Tampon pledget for increased bypass leakage protection

ABSTRACT

There is provided a tampon pledget that includes one or more enhanced features that result in the pledget exhibiting increased bypass leakage prevention. These enhanced features may include, but are not limited to, geometry, absorption, and any combinations thereof. There is also provided one or more methods for constructing a tampon pledget having increased bypass leakage protection.

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation application of pending U.S. patentapplication Ser. No. 16/777,957, filed Jan. 31, 2020, which is acontinuation of U.S. patent application Ser. No. 15/486,470, filed Apr.13, 2017, now U.S. Pat. No. 10,596,046, issued on Mar. 24, 2020, whichis a continuation of U.S. patent application Ser. No. 15/157,792, filedMay 18, 2016, now U.S. Pat. No. 9,687,389, issued on Jun. 27, 2017,which is a continuation of U.S. patent application Ser. No. 14/972,442,filed Dec. 17, 2015, now U.S. Pat. No. 10,076,452, issued on Sep. 18,2018, which is a continuation application of U.S. patent applicationSer. No. 12/958,897, filed Dec. 2, 2010, now U.S. Pat. No. 9,259,360,issued on Feb. 16, 2016, which is a continuation of U.S. applicationSer. No. 11/983,264, filed Nov. 8, 2007, now U.S. Pat. No. 7,867,209,issued on Jan. 11, 2011, which claims the benefit of U.S. ProvisionalApplication No. 60/857,694, filed Nov. 8, 2006, the contents of whichare hereby incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates generally to tampon pledgets. Moreparticularly, the present disclosure relates to tampon pledgets thatexhibit increased bypass leakage protection.

2. Description of Related Art

Both in-vivo and in-vitro testing has shown that current tampon pledgetsdo not protect well against bypass leakage. In-vivo testing shows thatthe typical woman places the tampon pledget too deep into the vaginalcanal and is not optimally placed to absorb fluid. In-vitro testingconfirms that tampon pledget expansion is not optimal. With both ofthese insights, it is known that there is a propensity for the tamponpledgets to leak prematurely, i.e., bypass leakage.

There have been many attempts in the prior art to address bypassleakage. Examples include providing a tampon pledget with variouspre-expanded, compressed shapes designed to conform to a user's anatomyupon insertion into the vagina. One particular drawback with the tamponpledget having a pre-expanded shape is that it may be difficult to housethe pre-shaped pledget in a typical cylindrical applicator barrel due toits shape. Also, once housed in the applicator, the tampon pledgethaving the pre-expanded shape may exert additional forces on the wallsof the applicator barrel due to its shape, which in turn could causeexcess friction during expulsion, requiring additional force to expelthe tampon pledget from the applicator. The required additional forcecould make use of the applicator difficult, and in some cases actuallycause deformation of the applicator, making its use extremely difficult.

Therefore, there remains a need in the tampon art for a tampon pledgetthat mitigates or all together prevents bypass leakage, while alsoavoiding the drawbacks associated with the prior art. The presentdisclosure meets this need.

SUMMARY OF THE INVENTION

The present disclosure provides a tampon pledget that exhibits increasedbypass leakage prevention.

The present disclosure also provides such a tampon pledget that hasincreased absorption potential at a base of the pledget.

The present disclosure further provides such a tampon pledget that hasincreased expansion potential at the base of the pledget.

The present disclosure still further provides such a tampon pledgetwhere the desired pledget geometry occurs post-expansion.

The present disclosure yet further provides such a tampon pledget withvarying fiber weight distribution across the length and/or width of thepledget.

The present disclosure also provides a method for assembling a tamponpledget that exhibits increased bypass leakage prevention.

These and other advantages and benefits of the present disclosure areprovided by a tampon pledget that includes one or more enhanced featuresthat result in the pledget exhibiting increased bypass leakageprevention. These enhanced features may include, but are not limited to,geometry, absorption, or any combinations thereof. The presentdisclosure also provides one or more methods for constructing a tamponpledget having increased bypass leakage protection.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is top view of pads positioned for a tampon pledget prior toformation of the tampon pledget according to the present disclosure.

FIG. 2 is a side view of one embodiment of a formed tampon pledgetaccording to the present disclosure.

FIG. 3 is a side view of another embodiment of a formed tampon pledgetaccording to the present disclosure.

FIG. 4 is a side view of yet another embodiment of a formed tamponpledget according to the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure provides a unique tampon pledget designed forvarious tampon sorts with one or more enhanced features including, butnot limited to, increased absorption potential at the base of thepledget, increased expansion potential at the base of the pledget, andany combinations thereof. These enhanced features are achieved byconstructing the tampon pledget with certain pad lay-up ratios, fiberweight distribution ratios, and any combinations thereof. As a result ofthese one or more enhanced features, a tampon pledget having increasedbypass leakage protection results. Additionally, the enhanced featuresdo not compromise the desired pledget geometry, or its pre-expansionability. Therefore, applicator modifications are not required to housethe tampon pledget of the present disclosure.

Referring to FIG. 1 , the present disclosure is exemplified by the padlay-up represented generally by reference numeral 10. Pad lay-up 10includes one or more bottom pads 12 and one or more top pads 14. Whilepad lay-up 10 depicts the one or more bottom pads 12 and one or more toppads 14 in a cross-pad configuration, it should be understood that thepad lay-up can be configured in any suitable shape, including, but notlimited to cross, chevron, diamond, circular, oval, square, rectangle,and any combinations thereof.

It has been unexpectedly found that by providing one or more bottom pads12 with one or more top pads 14 in certain pad lay-up ratios, and basedon their respective areas, various desirable tampon pledgetconfigurations can be achieved that provide enhanced bypass leakageprotection. Area is defined herein as length times width (without depthas a factor). The pad lay-up ratio is defined as the ratio of the areaof one or more bottom pads 12 to the area of one or more top pads 14,with the area of the one or more pads calculated in a single plane.Therefore, while stacking of multiple pads may be done, it does notincrease the calculated area of the one or more pads.

Again referring to FIG. 1 , the one or more top pads 14 each has alength dimension 15 and a width dimension 16. The one or more bottompads 12 each have a length dimension 17 and a width dimension 18.

In one embodiment, the one or more top pads 14 each have a lengthdimension 15 between about 2 inches and about 6 inches. In anotherembodiment, the one or more top pads 14 each have a length between about3.5 inches and about 5.0 inches. In yet another embodiment, the one ormore top pads 14 each has a length about 4 inches.

In one embodiment, the one or more top pads 14 each have a widthdimension 16 between about 1 inches and about 4 inches. In anotherembodiment, the one or more top pads 14 each have a width between about1.5 inches and about 3 inches. In yet another embodiment, the one ormore top pads 14 each has a width about 2 inches.

In one embodiment, the one or more bottom pads 12 each have a lengthdimension 17 between about 1 inch and about 4 inches. In anotherembodiment, the one or more bottom pads 12 each have a length betweenabout 2 inches and about 3 inches. In yet another embodiment, the one ormore bottom pads 12 each have a length about 2.5 inches.

In one embodiment, the one or more bottom pads 12 each have a widthdimension 18 between about 1 inch and about 4 inches. In anotherembodiment, the one or more bottom pads 12 each have a width betweenabout 1.5 inches and about 3 inches. In yet another embodiment, the oneor more bottom pads 12 each have a width about 2 inches.

In one embodiment of the present disclosure, the pad lay-up ratio isbetween about 1:1.2 to about 1:2.25. In another embodiment of thepresent invention, the pad lay-up ratio is about 1:1.6.

Another important aspect of the present disclosure is the fiber weightdistribution ratio between the one or more bottom pads 12 and the one ormore top pads 14. The fiber weight distribution ratio is defined as theratio of the fiber weight distribution of the one or more bottom pads 12to the fiber weight distribution of the one or more top pads 14.

In one embodiment according to the present disclosure, the fiber weightdistribution ratio is between about 0.5:1 to about 2:1. In anotherembodiment according to the present disclosure, the fiber weightdistribution ratio is between about 0.75:1 to about 1.5:1. In yetanother embodiment according to the present disclosure, the fiber weightdistribution ratio is about 1:1.

Suitable materials for use in forming the one or more bottom pads and/orthe one or more top pads include, but are not limited to, cellulosic,rayon, cotton, pulp, superabsorbent, absorbent foam, and anycombinations thereof.

The tampon pledget may include a liquid permeable coverstock or overwrapmaterial, if desired. Suitable coverstock materials may include, but arenot limited to, rayon, cotton, bicomponent fiber, or other suitablenatural or synthetic fibers known in the art. Rayon, polyethylene,polypropylene and blends of these are particularly suited for use as acoverstock material.

The following examples demonstrate various embodiments according to thepresent disclosure. These examples are not intended to limit the scopeof the present disclosure.

The pledget shape after exposure to moisture can vary according to theratios set forth above in accordance with the present disclosure.

Example 1

A tampon pledget 20 with a pad lay-up ratio of about 1:1.2 and fiberdistribution ratio of about 0.75:1 may be constructed. Referring to FIG.2 , tampon pledget 20 with these ratios will have straight wall sides toa slight teardrop or circular shape.

Example 2

A tampon pledget 30 with a pad lay-up ratio of about 1:2.25 and fiberdistribution ratio of about 1.5:1 may be constructed. Referring to FIG.3 , tampon pledget 30 with these ratios will have a teardrop shape.

Example 3

A tampon pledget 40 with a pad lay-up ratio of about 1:1.6 and fiberdistribution ratio of about 1:1 may be constructed. Referring to FIG. 4, tampon pledget 40 with these ratios will have a step-down multi-tieredto teardrop shape.

Comparative Examples 4 Through 6

Several commercial tampon pledgets were purchased from retail stores tobe used as comparative examples used to compare with tampon pledgets ofthis present disclosure. Comparative Example 4 tampons or tamponpledgets are Tampax Original (Super) tampons (available from Procter &Gamble); Comparative Example 5 tampons are Tampax Pearl (Super)Unscented tampons (available from Procter & Gamble); and ComparativeExample 6 tampons are Kotex Security Super tampons (available fromKimberly Clark).

Example 7

Approximately 60 tampon pledgets were constructed according to thepresent disclosure invention and tested. These are similar to thosedescribed in Example 1. These tampon pledgets were constructed with apad lay-up ratio of about 1:1.25 and a fiber distribution ratio of about1:1. Specifically, a bottom pad (2.25″×2.5″ from one Galaxy-based web)and a top pad (4″×1.75″ of a second Galaxy-based web) were used toconstruct these tampon pledgets. The top (or inside) pad moisture, asmeasured by a Halogen Moisture analyzer (Mettler-Toledo) was about9.78%. The bottom (or outside) pad moisture was 11.55%. Tampon pledgetweights were 2.60 g (average)+/−0.03 g (one standard deviation). Thetampon pledgets were all constructed as outlined herein, according tothe present disclosure.

To form the tampon pledgets of the above Examples, individual pads werearranged in a crosspad configuration according to the present disclosureinvention and carefully weighed. Using a Hauni machine, the crosspadtampon pledget was delivered and folded, using an appropriately sized(about 0.25″) fluted ram, into a cylindrical shaped transfer tube toform a cylindrical tampon pledget. The pledget was then transferredagain using another ram into a warmed oven tube (inside diameter about0.5″, temperature about 220° F.) and then conveyed by a pre-heated IRconveyor oven (Infrared Heating Technologies, LLC). This heated,compressed cylindrical tampon pledget was then transferred into aslightly larger diameter stringer tube. In this tube, a needle waspierced through to permit a Nalan-coated string to be added and tied.Following the addition of string, the tampon pledget was added to astandard Gentle Glide™ plastic applicator. The petals on the applicatorwere then heated to about 200° F. and shaped, to “close” them. Thesefinished tampon pledgets were stored for at least one day. Then testing,as outlined above, was performed.

Syngyna absorbency was evaluated according to the usual FDA mandatedtesting procedure, as outlined in the Federal Register, Part 801,801.430. The Syngyna absorbency, measured for 20 such tampon pledgets,was 10.93+/−0.29 grams, consistent with a super absorbency tamponpledget.

A modified syngyna absorbency test, known as the positive displacementtest, was performed. In this modification of the usual FDA procedure,instead of circulating the 27° C. water continuously inside the tubearound the condom that encases the tampon pledget, the water wasdirected to a burette, which was located three inches higher than thetop of the syngyna tube. The water level in this burette was adjusted tothe zero level at the start of the syngyna experiment. Then, as thetampon pledget expanded to form a shape similar to the teardrop shape ofFIG. 3 , the water level in the tube increased. This increase wasmonitored every thirty seconds.

The purpose of this test was to see how rapidly the volume of the tamponpledget expanded during a syngyna absorbency experiment and to comparethese results with those for comparable commercial tampon pledgets setforth in Comparative Examples 4 through 6.

Table 1 below provides these results. Twenty tampon pledgets for each ofthese examples were tested using the procedure outlined above. Sincetampon pledget weights vary slightly from manufacturer to manufacturer,Table 1 reports normalized slopes; that is, the rate of volumetricincrease vs. time was divided by the average pledget weights, to reportthe rates of increase in an even-handed manner. As the Table shows,tampon pledgets of the present disclosure exhibit a rate increase thatis statistically significantly higher than existing commercialofferings. Notably, the average positive displacement rate is greaterthan 0.145. Preferably, the average displacement rate is greater thanabout 0.2.

TABLE 1 Positive Displacement Results for Various Super AbsorbencyTampons Positive Displacement Rate (ml increase per minute weight ofpledget, (ml/min/gram)) Average % relative Standard to that for ExampleManufacturer Average Deviation Example 7 Comparative 4 Procter & Gamble0.073 0.021 36.3% Comparative 5 Procter & Gamble 0.141 0.048 69.7%Comparative 6 Kimberly-Clark 0.064 0.015 31.6% Example 7 PresentInvention 0.202 0.034 100.0% 

The tampon pledgets according to the present disclosure, as exemplifiedby Example 7 in Table 1, have the majority of the absorption potentialnear the bottom of the tampon pledget. As a result of arranging theabsorbent material of each tampon pledget in such a manner it promotesan expansion of the pledget that reduces bypass leakage.

The positive displacement in vitro test suggests that tampon pledgets ofthe present disclosure expand more rapidly than tampon pledgets made byalternative means. Moreover, the observed shapes that these tamponpledgets take during expansion (see Figures), owing to the modifiedweight and area distributions—together with in vivo results—suggeststhat tampon pledgets of the present disclosure should be more suitable“plugs” and thus provide more effective bypass leakage prevention.

While the present disclosure has been described with reference to one ormore exemplary embodiments, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted for elements thereof without departing from the scope of thedisclosure. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the disclosurewithout departing from the scope thereof.

What is claimed is:
 1. A compressed tampon pledget, comprising: at leastone bottom pad having a length that is between about 1 inch and about 4inches, a width that is between about 1.5 inches and about 3 inches, theat least one bottom pad having a bottom area calculated in a singleplane and a bottom fiber weight distribution; at least one top pad witha length that is between about 3.5 inches to about 5 inches, a widththat is between about 1.5 inches to about 3 inches, the at least one toppad having a top area calculated in a single plane and a top fiberweight distribution; wherein a fiber weight distribution ratio of the atleast one bottom pad and the at least one top pad is between about0.75:1 and about 1.5:1; wherein the compressed tampon pledget has anaverage positive displacement of greater than 0.145.
 2. The compressedtampon pledget of claim 1, further comprising a pad lay-up ratio of thebottom area to the top area of 1:2.25.
 3. The compressed tampon pledgetof claim 1, further comprising a pad lay-up ratio of the bottom area tothe top area of 1:1.6.
 4. The compressed tampon pledget of claim 1,further comprising a pad lay-up ratio of the bottom area to the top areaof 1:1.2.
 5. The compressed tampon pledget of claim 1, wherein the fiberweight distribution ratio of the at least one bottom pad and the atleast one top pad is between about 0.75:1.
 6. The compressed tamponpledget of claim 1, wherein a fiber weight distribution ratio of the atleast one bottom pad and the at least one top pad is between about1.5:1.
 7. The compressed tampon pledget of claim 1, wherein a fiberweight distribution ratio of the at least one bottom pad and the atleast one top pad is between about 1:1.
 8. The compressed tampon pledgetof claim 1, wherein the compressed tampon pledget has a greaterexpansion potential near a bottom end of the compressed tampon pledgetthan a top end.
 9. The compressed tampon pledget of claim 1, wherein thecompressed tampon pledget has a higher absorption potential at a bottomend of the compressed tampon pledget than at a top end.
 10. Thecompressed tampon pledget of claim 1, wherein the compressed tamponpledget is generally cylindrical such that a main body region of thecompressed tampon pledget has a wall side that is generally straight,wherein the wall side leads into an adjacent insertion end such that themain body region transitions into at least one of a slight teardropshape, a teardrop shape, and a circular shape.
 11. The compressed tamponpledget of claim 1, wherein the average positive displacement rate isequivalent to a volumetric rate increase of the compressed tamponpledget in a modified syngyna absorbency test divided by a dry weight ofthe tampon pledget.
 12. The compressed tampon pledget of claim 11,wherein the compressed tampon pledget has an average positivedisplacement of greater than 0.2.
 13. The compressed tampon pledget ofclaim 1, wherein prior to folding the at least one bottom pad and the atleast one top pad to form the compressed tampon pledget, the at leastone top pad and the at least one bottom pad are in a cross-padconfiguration, wherein the cross-pad configuration has an overlapportion that is formed where the at least one top pad and the at leastone bottom pad overlap and a plurality of non-overlap portions areformed on opposite sides of the at least one top pad and the at leastone bottom pad where the at least one top pad and the at least onebottom pad do not overlap such that the at least one bottom pad and theat least one top pad provide an arrangement of an absorbent materialresulting in the fiber weight distribution, the compressed tamponpledget thereby configured to expand into a slight teardrop shape uponliquid absorption.
 14. The compressed tampon pledget of claim 13,wherein the cross-pad configuration is folded within a fluted ram. 15.The compressed tampon pledget of claim 13, wherein the cross-padconfiguration is folded, compressed, and heated to form a shaped tamponpledget.
 16. The compressed tampon pledget of claim 15, wherein theheating is to about 220° F.
 17. The compressed tampon pledget of claim1, wherein the compressed tampon pledget has an insertion tip regionhaving an insertion tip end and an insertion rearward end, a main bodyregion having a main forward end and a main rearward end, and awithdrawal region having a withdrawal forward end and a withdrawalrearward end, the insertion rearward end is adjacent the main forwardend, and the main rearward end is adjacent the withdrawal forward end,the compressed tampon pledget has a maximum diameter of the insertiontip region and the main body region where the insertion rearward end andthe main forward end meet.
 18. The compressed tampon pledget of claim17, wherein the main body region tapers from the maximum diameter to aminimum diameter and thereafter increases to a middle diameter that isgreater than the minimum diameter.
 19. The compressed tampon pledget ofclaim 1, wherein at least one of the at least one top pad and at leastone of the at least one bottom pad comprise, cellulose, rayon, cotton,pulp, absorbent foam, and combinations thereof.
 20. The compressedtampon pledget of claim 19, wherein at least one of the at least one toppad and at least one of the at least one bottom pad comprise a GALAXY®based web.